MOOC on 3D Printing and Design for Educators

Self-Instructional Module (e-Content)

COURSE: 3D Printing and Design for Educators

UNIT-2: Data Preparation for 3D Printing

Dr. Sharad K. Pradhan

Professor, Dept. of Mechanical Engineering
National Institute of Technical Teachers’ Training and Research,
Shamla Hills, Bhopal M.P.INDIA 462002

Dr. Ankit Nayak

Post-Doctoral Fellow, The University of Hong Kong, Hong Kong
Assistant Professor (Sabbatical), School of Automation
Banasthali Vidyapith University, Rajasthan, INDIA

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 MOOC on 3D Printing and Design for Educators

INDEX

Unit2: Data Preparation for 3D Printing

Lesson Title of Lesson Marks Page

No. No.
2.1 STL file format and Associated Operations
2.2 Part orientation and Support Generation
2.3 Slicing and Deposition Path Generation

Unit Learning Outcomes

After going through the E-Content, Videos, Assignments and Discussion topics presented
in this unit, the learner will be able to

a) Create .stl file formats for 3D printing.

b) Optimize part orientation in 3D printing process planning software, ensuring higher
quality prints and more efficient use of resources.
c) Generate supports for effective 3D printing of parts.
d) Use effective method for slicing the CAD model.

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Lesson 2.2

Part Orientation and Support Generation

2.2.1 INTRODUCTION

Part orientation refers to the positioning of an object on the build platform during the 3D
printing process. It is essential to understand that the orientation of the part directly impacts its
build quality, processing, and post-processing. Moreover, the chosen orientation affects
support generation, as different angles and positions may require varying levels of support
material. Properly oriented parts can minimize the need for support structures, reducing
material consumption and post-processing efforts.

When fabricating multiple copies of the same part or different parts simultaneously, proper
placement and orientation become critical steps in 3D printing. This is because they help to
maximize the use of the build volume, allowing for the efficient production of several parts at
once. Additionally, optimal part orientation and placement can streamline the slicing process,
as the software will be able to generate more precise toolpaths for the composite models.

In this lesson, we will explore the significance of part orientation and its impact on 3D printed
parts, the support required for overhanging features, and the slicing process for composite
models. By understanding the relationship between part orientation, support generation, and
slicing, you can make informed decisions when preparing your 3D models for printing,
ultimately enhancing the final product's quality and efficiency.

2.2.2 PART ORIENTATION

In 3D printing process planning software, there are various methods available to help align the
proper part orientation. These methods can be divided into two categories: manual methods
and automatic methods. As the name suggests, manual methods involve using various
transformation operations, such as move, rotate, and copy, to align and place parts manually
on the build platform. On the other hand, automatic placement methods employ algorithms to
position the part on the build platform correctly based on specific parameters. These
parameters may include minimizing support structures, maximizing strength in a particular
direction, minimizing the bounding box, reducing surface area, and minimizing the x or y
dimensions.

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By understanding and utilizing these two categories of methods, users can effectively optimize
part orientation in 3D printing process planning software, ensuring higher quality prints and
more efficient use of resources.

(i) Manual Placement Methods

In manual placement, the part is modified using the primary transformation operations, such as
Translation, Rotation, Mirroring, and Scaling. Process planning software applies these
operations by multiplying the transformation matrix with the part coordinates. As an example,
Figure 1 illustrates the menu options in Cura software, where it displays the graphical user
interface (GUI) icons for Move, Scale, Rotate, and Mirror commands, respectively.

By utilizing these manual placement tools, users can effectively adjust the orientation and
position of their 3D models within the process planning software, ensuring optimal results
during the printing process.

Figure 1: Menu option in Cura software showing Move (Translate), Scale, Rotate and
Mirror options (Top to bottom) respectively

Move – Move is used to translate the part from one place to another on the build plate form. It
used a transformation matrix:

1 0 0 𝑇𝑇𝑇𝑇
0 1 0 𝑇𝑇𝑇𝑇
𝑇𝑇 = � �
0 0 1 𝑇𝑇𝑇𝑇
0 0 0 1

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In this matrix Tx, Ty, and Tz represent the translation distances along the x, y, and z axes,
respectively. To apply the translation to a 3D point (x, y, z), you can multiply this transformation
matrix with the point's coordinates in the form of a 4x1 column vector.

So in software, you need to define Tx, Ty and Tz as showing in the following figure.

Figure 2: Cura screenshot showing translation parameters in red box

Scale – Scale is used to increase and decrease the size of the object on the build platform by
defining the scale dimensions or scale factor. The transformation matrix for scale is as follows:

𝑆𝑆𝑆𝑆 0 0 0
0 𝑆𝑆𝑆𝑆 0 0
𝑆𝑆 = � �
0 0 𝑆𝑆𝑆𝑆 0
0 0 0 1

In this matrix, Sx, Sy, and Sz represent the scaling factors along the x, y, and z axes, respectively.
To apply the scaling to a 3D point (x, y, z), you can multiply this transformation matrix with the
point's coordinates in the form of a 4x1 column vector.

In Cura software you can define the scaling parameters along x, y and z direction as shown in
figure 3.

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Figure 3: Cura screenshot showing scale parameters.

As illustrated in Figure 3, it is important to observe that there are two types of scaling that can
be applied along the axis of an object: uniform and non-uniform scaling. When the uniform
scaling option is selected, it ensures that the parameters along the x, y, and z directions are
altered in a consistent manner, maintaining the object's proportions. On the other hand, if you
choose not to apply uniform scaling, you will need to define distinct parameters for each axis
independently.

It is crucial to be aware that non-uniform scaling can lead to the distortion of the object's
shape, as it modifies the dimensions along each axis differently. This may result in an altered
appearance that deviates from the original design. Therefore, it is essential to carefully consider
the desired outcome when selecting the appropriate scaling method for your object.

Rotation - Rotation is used to change the orientation of an object on the build platform by
defining the rotation angles. The transformation matrices for rotation around the x, y, and z
axes are as follows:

Rotation around x-axis (angle θx):

1 0 0
𝑅𝑅𝑅𝑅 = �0 cos(𝜃𝜃𝜃𝜃) − sin(𝜃𝜃𝜃𝜃)�
0 sin(𝜃𝜃𝜃𝜃) cos(𝜃𝜃𝜃𝜃)

Rotation around y-axis (angle θy):

cos(𝜃𝜃𝜃𝜃) 0 sin(𝜃𝜃𝜃𝜃)
𝑅𝑅𝑅𝑅 = � 0 1 0 �
− sin(𝜃𝜃𝜃𝜃) 0 cos(𝜃𝜃𝜃𝜃)

Rotation around z-axis (angle θz):

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cos(𝜃𝜃𝜃𝜃) − sin(𝜃𝜃𝜃𝜃) 0
𝑅𝑅𝑅𝑅 = � sin(𝜃𝜃𝜃𝜃) cos(𝜃𝜃𝜃𝜃) 0�
0 0 1
In these matrices, θx, θy, and θz represent the rotation angles around the x, y, and z axes,
respectively. To apply rotation to a 3D point (x, y, z), you can multiply the corresponding
transformation matrix (or a combination of these matrices) with the point's coordinates in the
form of a 4x1 column vector.

The rotation process enables you to precisely control the object's alignment and orientation
within the 3D space. By adjusting the rotation angles around each axis, you can achieve the
desired position for your object on the build platform. This is particularly useful for optimizing
the object's placement for manufacturing or assembly purposes, ensuring a seamless fit with
other components or maximizing the use of available build space.

In Slicer software the object can be rotate interactively by dragging the rotation circles that
indicated in red, green, and blue colors. As shown in figure 4.

Figure 4: Rotate menu of Cura software, red, green, and blue circles showing interactive rotation path.

It can also be decided in the software that which face you want to lay on the bed. By pressing ( )
button it places a face of the part on the bed automatically. Additionally, the next icon ( ) is used to
place a particular face on the platform.

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Mirror - Mirroring is used to create a reflection of an object on the build platform by defining
the mirror planes. The transformation matrices for mirroring along the x, y, and z planes are as
follows:

Mirror along x-axis:

−1 0 0
𝑀𝑀𝑀𝑀 = � 0 1 0�
0 0 1
Mirror along y-axis:

1 0 0
𝑀𝑀𝑀𝑀 = �0 −1 0�
0 0 1
Mirror along z-axis:

1 0 0
𝑀𝑀𝑀𝑀 = �0 1 0�
0 0 −1
In these matrices, the values along the diagonals represent the mirror planes along the x, y, and
z axes, respectively. To apply mirroring to a 3D point (x, y, z), you can multiply the
corresponding transformation matrix (or a combination of these matrices) with the point's
coordinates in the form of a 3x1 column vector.

The mirroring process enables you to create a symmetric copy of the object within the 3D
space. By reflecting the object along each axis, you can achieve the desired reflection for your
object on the build platform. This is particularly useful for creating symmetrical designs,
generating opposite-handed parts for assembly, or optimizing the object's placement for
manufacturing purposes.

In Cura software there is interactive arrows that mirror the object about principle planes as
showing in figure-

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Figure 5: Interactive arrows to create mirror object.

(ii) Automatic Placement Methods

In addition to manual operations, some software programs, such as Materialise Magics, offer
built-in automatic operations for placing parts on the build platform. With the automatic
placement feature, parts can be efficiently nested on the platform. Two nesting options are
available:

1. Geometry-based nesting

2. Bounding box-based nesting

Remember that when importing multiple parts, you can use the automatic placement algorithm
to instantly position them on the platform. Even if the platform isn't large enough to
accommodate all parts, the software will search for a solution beyond the platform borders,
arranging the parts for optimal viewing.

Bounding box-based nesting can lead to wasted capacity if a part has a large bounding box but
a small projected area. In contrast, Magics uses the actual form of the parts for geometry-based
nesting, resulting in more efficient use of space.

Alternatively, Magics can represent parts by their bounding boxes, leading to faster nesting.
However, this method may not fully utilize the available surface area of the machine due to the
rough representation of the parts.

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The automatic part orientation algorithm in 3D printing software is designed to optimize the
orientation of objects based on various objectives. Three popular models for achieving optimal
orientation include:

1. Cost Minimization Model

2. Support Minimization Model

3. Multi-Objective Model

Cost Minimization Model-The Cost Minimization Model aims to reduce the overall cost of
producing a 3D printed object. The cost function for 3D printing can be expressed as follows:

Total Cost = Preprocessing Cost + Machine Utilization Cost for Building the Part + Material Cost
+ Post-processing Cost

Preprocessing Cost = (Model Positioning Time + Support Generation Time + Model Slicing Time
+ Tool Path Generation Time) × (Staff Cost + Facility Cost) + Machine Setup Time × (Staff Cost +
Machine Utilization Rate)

Build Cost = Build Time × Machine Utilization Rate

Material Cost = Cost of Modeling Material + Cost of Support Material

Post-processing Cost = Post-processing Time × Staff Cost + Cost of Other Materials and Facilities
(e.g., water, heat source, etc.)

In the Cost Optimization Model, the goal is to minimize the total cost of printing the part. The
objective function aims to minimize the overall cost, subject to the variables of orientation
along the x, y, and z directions, and the angular position of the object along the principal axis.

By utilizing these models, 3D printing software can automatically determine the most efficient
and cost-effective orientation for objects, ensuring optimal use of resources and minimizing
production costs.

Support Minimization Model- We know that the volume of support is depends on the
projected area of overhanging part and it can be determined from the following equation:
𝑛𝑛 𝑛𝑛

𝑉𝑉𝑉𝑉 = � 𝑉𝑉𝑖𝑖 = � 𝐴𝐴𝑖𝑖 × ℎ𝑖𝑖

𝑖𝑖=1 𝑖𝑖=1

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In the context of an STL file, let us consider a scenario where 'n' represents the total count of
downward-facing facets that necessitate support structures. For each individual facet i, we can
denote its projected area on the horizontal slicing plane as Ai. Additionally, we must take into
account the average support height (hi), which is determined by evaluating the corresponding
facet in relation to either the platform or the next intersecting facet, depending on which of the
two exhibits a lesser height. By comprehensively analyzing these parameters, we can gain a
more in-depth understanding of the various facets and their structural requirements within the
STL file.

Here the objective function will be minimization of the Ve by optimizing the variables related to
part orientation.

Multi Objective Model- In a multi-objective model, the orientation of a part is optimized by

considering multiple objectives and applying suitable weighting criteria. These criteria can
include the following:

• Maximizing the number of perpendicular surfaces.

• Maximizing the number of upward-facing horizontal surfaces.
• Optimizing the alignment of hole axes in the build direction.
• Maximizing the number of curved cross-sections illustrated in the horizontal
plane.
• Maximizing the area of the base surface.
• Minimizing the slope of the base surface.
• Minimizing the overall build volume.

By incorporating these criteria, the model ensures an optimized orientation of the part that
accounts for various design factors and objectives.

Materialize Magics is a professional software that have many features and inbuilt algorithms to
automatically align the part from their manual we are discussing some important commands
that used to set the orientation of the model(s) on the build platform.

Minimizing Bounding Box-The orientation of the part will be adjusted to minimize its bounding
box while maintaining the original scale of the part. This approach aids in streamlining the
quoting process and enhancing the efficiency of build preparation.

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Figure 6. Minimizing Bounding Box (Image taken from Materialise Magics user Manual)

The shape sorter is a specialized tool of Materialise Magicsengineered to organize components

with comparable geometries. To initiate the sorting process, a primary or "master" part is
designated as a reference. Subsequently, the remaining selected parts are systematically
arranged around this master part, taking its orientation into account.

Once the parts are organized according to the master part's orientation, an option to group
these components becomes available. This grouping feature facilitates efficient nesting of the
parts on the build platform. By implementing this nesting strategy, users can optimize the
arrangement and placement of parts, ultimately enhancing the overall utilization of the
platform's available space.

In essence, the shape sorter simplifies the organization of parts with similar geometries by
using a master part as a reference point, then enabling users to group and nest the components
effectively on the build platform for maximum efficiency.

Figure 7. Shape sorter (Image taken from Materialise Magics user Manual)

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3D Nester - The Magics 3D Nester software guarantees an optimal loading configuration for your
sintering machines. Taking into account the geometry of each part, the software intelligently nests your
components to maximize the quantity of parts within the build envelope and/or minimize the overall
build time. Simultaneously, the software ensures that none of the parts come into contact with one
another or the container, effectively preventing any potential collisions.

2.2.3 SUPPORT GENERATION

The support structure is primarily necessary for creating overhanging features in additive
manufacturing. As discussed in earlier sections, some AM processes do not require explicit support
structures. At times, it can be managed by orienting the part in such a way that it eliminates the
presence of overhanging features.

For any STL part and build direction, the support structure can be easily calculated based on the facet
normals of the triangles in the STL file and the build direction. If the build direction is vertical, triangles
with normals pointing upward will not require support, while those with normals pointing downward
may necessitate a support structure.

Each additive manufacturing process utilizes different types of materials, and these materials can
withstand varying degrees of overhang. Consequently, the necessity of support structures for
overhanging parts may depend on the material and process parameters, such as slice height. In some
cases, support materials may not be required for overhanging features, depending on the specific
material and process parameters employed.

In Cura software, there are two types of support structures: column-type support and tree support.
When generating support structures, users must define various parameters, including the support
material extruder, support angle, support pattern, support density, support horizontal expansion,
support infill layer thickness, gradual support infill steps, and gradual support infill height. Additionally,
users can choose to enable or disable options such as support interface, support roof, and support floor
by checking or unchecking the corresponding boxes in the software.

Select from the available techniques to generate support structures for your 3D model. The "Normal"
support method constructs a support structure directly beneath the overhanging parts, extending those
areas vertically downwards. In contrast, the "Tree" support method forms branches that reach toward
the overhanging areas, providing support at the tips of the branches. This approach allows the branches
to maneuver around the model, ensuring maximum support from the build plate whenever possible.

The support placement setting adjusts the positioning of the support structures. Users can choose
between "Touching Build Plate" or "Everywhere" for the placement options. When set to "Everywhere,"
support structures will also be printed on the model itself, providing additional support where
necessary.

Support angle parameter is self-explanatory that indicate the minimum inclination angle of the facet for
which support is needed to define. Support density and support pattern helps to change the support

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parameters like support infill pattern can be changed by changing the support pattern while density
change the infill density of support structure.

Figure 8. Normal (left) and tree (right) support generated by Cura software.

Support generation plays a pivotal role in additive manufacturing processes, such as Stereolithography
and metal sintering. The ability to rapidly and efficiently create support structures is equally vital in
Rapid Prototyping. The final quality of a part hinges on the accurate verification and adaptation of the
generated support structures. MaterialiseMagics software provides an array of support types, allowing
users to utilize various combinations of these different support structures on a single surface to optimize
the manufacturing process and ensure the highest possible part quality.

Throughout this lesson, we have examined the crucial role that part orientation and support generation
play in 3D printing. As we have discovered, part orientation has a significant impact on various aspects
of 3D printed objects, including build quality, processing, and post-processing, as well as determining
the necessary support structures.

By appropriately orienting parts, material usage and post-processing efforts can be minimized, as the
need for support structures is reduced. In scenarios where multiple parts or different components are
being produced simultaneously, efficient placement and orientation are essential to maximize build
volume utilization and improve the slicing process, leading to precise toolpaths for composite models.

To conclude, a comprehensive understanding of the relationship between part orientation, support

generation, and slicing is key to making well-informed decisions when preparing 3D models for printing.
By taking these factors into account, you can enhance the quality and efficiency of your final product,
ensuring the success and cost-effectiveness of your 3D printing endeavors.

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Assignment 2.2.1:
- How can different part orientations affect the efficiency of a 3D printing
process in terms of support structures, build time, and material
consumption?
- What strategies can be employed to optimize the placement and orientation
of multiple components within a single print job to maximize build volume
usage and minimize support material and post-processing requirements?

References:

1. Materialise Magics 26 User manual found at:

https://static.helpjuice.com/helpjuice_production/uploads/upload/image/5908/direct/1652962
888547-Magics_manual.pdf accessed on 20 February 20, 2024 at 9:26 am (GMT)

2. Soni S, Nayak A, Taufik M. Development of graphics user interface (GUI) for process planning in
extrusion based additive manufacturing. Materials Today: Proceedings. 2022 Jan 1;49:403-11.

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